Process of bonding rails.



W. BQ CLEVELAND.

PROCESS OF BONDING RAILS.

APPLICATION EILED JUNE 12, 1909.

ggggn Patented June 13, i911.

2 SHEETS-SHEET 1.

W. B. CLEVELANDu PROCESS OP BONDING RAILS.

APPLICATION FILED JUNE 12, 1909.

Patented June 13, 19M'.

2 SHEETS-SHEET 2.

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Spec'leatcn of Letters Patent. Patented June 13, 1911.

Application filed .Tune 12, 1909. Serial No. 501,700.

To all evwm 'it may concern/.-

Be it known that I, WILLIAM B. CLnvn- LANDa citizen of the United States, resident of Cleveland, county of Cuyahoga, and State of Ohio, have invented a new and useful lmprovement in Processes of Bonding Rails, of which the following is a specilication, the principle of the invention being herein eX- plained and the best mode in which l have contemplated applying that principle, so as to distinguish it 'from other invent-ions.

The present invention relates to a method of making homogeneous mechanical junctures between two metallic bodies, and is particularly adapted to the joining together of copper bonds and steel rails so as to bring the electrical conductivity of the abutting rails up to the required degree The objectof 4the invention is to provide such a bonding process that may be carried on in arapid and eflicient manner.

To the accomplishment of these and related ends, said invention, then, consists of the means hereinafter fully described, and particularly .pointed out in the claims.

The general process of making a homogeneous mechanical juncture, of which the present process maybe regarded as being one specific aspect, is fully described and claimed in a co-pending application of Albert li.

Herrick, filed November 25,1904, Serial No; n

234,161. The present process may be regai-ded as being, in a sense, the adaptation of such general process to the application of bonds of the socket-connected type incontra-distinction to the applicationof surface.`

connected bonds. The general process of which the one in hand is thus a specic as peet, is to be distinguished from processes of soldering bonds to rails, whether by electrical or other means; for by a homogeneous mechanical juncture, I mean to designate a union between the metals more intimate than that secured at the low temperature at which solder will melt. In other words, by my present method-or process, l am enabled to obtain a true weldedjoint between the copper of the bond and the steel of the rail, while at the same time, the ease of operation is such that the bonding may be carried on at a much increased rate of speed.

The annexed drawings and the following description set forth in detail certain mechanism embodying the invention, such disclosed means constituting, however, but one of various mechanical forms in which the principle of the invention may be used.

In said annexed drawings Figure l represents a vertical transverse cross-section of a standard steel rail, with a bond of the type in hand applied thereto and in position for the bonding process; in this figure I have such bond is represented as already ailixed or welded to t-he corresponding rail, the latter appearing in dotted outline only. Fig. 3 is a'transverse cross-section of bond and rail, similar to that of Fig. 1, except that the bond terminal is likewise sectioned, and shown as aiiixed or welded in place. Fig. 4 is a diagrammatic view showing an arrange ment of circuit adapted to the carrying o n ci my improved process. Fig. 5 illustrates a modification in the construction of the apparatus employed in carrying on the process adapting Vthe same to use with a slightly modiied form of bond. And Figs. 6,- 7, 8, 9 and 10 respectively illustrate other moditications et the apparatus designed for operation in conjunction with still other types of bond,

As has been indicated, the bond, for the affixing of which the present process is more especially designed, is that known as a socket-connected bond, or as they are known to the trade, studterminal bonds. bonds, as heretofore applied, have depended upon the physical contact between the copper and steel for their electrical connection. ln the case where the st-uds forming the 'terminals of the bond are solid, a compression stress is applied, sulicient to cause the copper of the terminal to expand and flow laterally until it bears against the annular Walls of the hole, wherein such termina-l is to be secured; while in the. case of tubular studv terminal bonds, a pointed or tapered punch somewhat larger than the diameter of the hole in the terminal', is used to produce the desired expansion.4 Bonds of the general class just described, viz. socket-connected bonds, may be applied either to the Such s ico web of the rail, in which case they are generally inclosed by the fish -plates at the joints, or else said bonds are attached to the ball or flange of the rail. rlihe particular mode ot' attachment adopted is obviously a matter of indifference in the present connection, and while in the several illustrations of apparatus for the carrying on of my improved process, I only show the bond as being applied to the web and to the ball of the rail, it is not meant to imply any limitation of the process to use in these particular connections. For the sake of further diversity moreover, illustrate the process as adapted to the several different kinds of terminals to which reference has been made, viz. the solid terminal (shown in Figs. 1 to 3 inclusive) a hollow terminal, not entirely perforated, however, (shown in Fig. 5) g and a completely perforated, or tubular, terminal (shown in Fig. 6).,

Having reference, then, first of all to Figs. 1, 2 and 8, the bond A there illustrated will be seen to represent an approved type of connection for use beneath the iish plates of the rails in the fashion to which allusion has been previously made, the terminals of the bond being in the form of solid studs a and the body a consisting of laminations formed by winding a narrow strip or strand of copper around and around upon itself. in place of such laminated body structure, a cable or solid rod is frequently employed. in carrying out the present process, the head a of the bond is inserted in an aperture b of the rail B to which it is to be secured, the relative diameters of head and aperture being such as to permit such insertion to be easily made. Thereupon the heating device now to be described is caused to press against opposite ends of said head and the welding operation undertaken. Of such heating device, only those parts are shown as are directly associated in the bonding operation, the parts in question consisting of two movable members or clamp arms c c, a holder c2 removably clamped to the lower end of one of said members, and a block c3 of high resistance material, preferably carbon, adjustably secured in said holder. A. suitable source of electricity, as a dynamo C', being provided for passing a current through a circuit including said carbon (see Fig. d), the latter may be raised to any desired degree of temperature, owing to the resistance interposed by the material of which it is made to the passage of such current therethrough. ril`he actual operation of bonding by the form of the present process illustrated in Figs, l, 2 and 3 will accordingly be seen to involve clamping ,the bond terminal between such two members c, c with the carbon block c3 so disposed as to contact with the free end of the terminal stud a, while the other member is broughtceases up against the head proper'of the bond, and under suiiicient pressure to secure good electrical contact therewith. The passage of a heating electric current through the clamping arms c 0, the interposed electrode c3 and bond terminal a serves to raise such electrode to a high temperature in which it assumes a-more or less incandescent state, and thus to heat the terminal. The latter owing to its relatively high heat conductivity then conducts the heat thus received to the surface of the railbounding the aperture therein, so that said terminal and such surface are brought to a welding temperature prac-4 tically simultaneously. At the same time, owing to the pressure exerted from either side upon ther terminal by the heating device, and owing to the further fact that in its normal condition said terminal is formed to project a slight distance through the aperture in the rail, the material of the terminal as soon as it becomes sufficiently plastic is pressed radially outward against such bounding surface of the aperture, thus insuring a thorough union between the bond and the raii. rihe amount of extra material provided in the terminal by reason of its thus extending through the rail is approximately sufficient to take up the space that would otherwise persist between said terminal and the bounding surface of the aperture, so that upon completion of the operation a finished appearance is given the attached bond terminal as shown in Fig. 3.

lWhere bond A is provided with a hollow terminal a2 in Fig. 5, or a tubular terminal a8, lFig. 6, mechanical means are required for pressin the material of said terminal outwardly into contact with the bounding surface of the aperture instead of relying upon the compression of such material in the confined space provided by the aperture, as is possible with the solid stud terminal illust-rated in Figs. 1, 2 and 3. lid/'here the bond terminal is simply hollowed out and 'not entirely perforated, li. provide the inner end of electrode c3 with a projection c* adapted to enter the recess in the terminal, the function of which will be obvious. Projection cAx is preferably formed separate from the body of the electrode, and may be carried by a disk-like member or button c having substantially the same cross sectional area as the electrode, (Fig. 5), or it may bear directly against the electrode (Fig. G). lin this way the liability that would otherwise be present for such projection to break off in case the electrode were not brought up squarely, is in large part overcome. lVhile.

the same construction of electrode, for obviously the projection et, with or without button c5 constitutes in effect but a part of said electrode, would be equally well adapted for the tubular form of terminal a3 shown in Fig. 6, l preferably here vary the. form aperture or scenes of the projection by providing the same with an outer inclined face, and then utilize in connection therewith an additional member in the form of a short block or rod c of carbon having a com lementary inclined face.

lVhen now the material of the terminal becomes plastic, the etl'ect of the pressure of the clamping members upon :the opposite ends of the terminal, Will be to force members et. c of the electrode 'past each other, and thus exert the desired outwardly expansive force upon the material of the terminal. lilith either of the two types of bond illustrated in Figs. 5 and 6, l, may, moreover', substitute carbon c7 in a gramilated or powdered condition for the solid projection o4 and block c (see Fig. 8).

In Fig. 7, l illustratea known type of bond designed to be laterally attached to the ball of the rail, such attachmentin the prevailing practice being secured as heretofore explained, in connection with the general description of the installation of 'stud terminal bonds. In other words, after the ,terminal of the bond has been inserted in the blind recess therefor provided in the rail ball, such terminal is expanded with a riveting hammer or compressor. There is, of course, nothing more than a physical contact between theV copper and the steel rail obtained, just as in the case of the other types of bond, when applied in the usual manner. ln adapting my present process to this type of bond, the one clamp member c is brought up against the opposite side of the ball b2 of the rail from that in which the aperture Z1 is formed; while the other clampino' member c that bears the electrode is brougit up so as to cause the inner end of the electrode to bear against the bond terminal, in this case the head end of such terminal, instead of the outer free end. As before ther conductivity of the terminal is found to be such that the contacting surface of the aperture is brought to a welding temperature practically simultaneously with the terminal, so that a homogeneous juncture of the terminal with the rail is secured in contradistinction to the mere physical contact heretofore obtained.. rl`he bond terminal may be tubular here also, in which case a modification in the electrode is made similar to that shown in the preceding figures (see lfig. El). v

ln Fig. l0, iin-ally, l show the adapt-ation' of my process to the welding of stud-terminal bonds in a horizontal position, as for example to the ange of a rail, although the specific form of rail B there illustrated is that largely employed in the conduits of underground trolley systems. lVhere the bond is to be attached in such horizontal position. the terminal is preferably introduced from below through the aperture b4 in the rail flange b5, said terminal as before being prefshown as'tapered, whereby the desired raf dial expansion of the material is obtained.

In practicing this form of the process, I find that it is feasible to heat the terminal beyond the welding temperature so 'as to even fuse the same, if desired.

It will, accordingly, be observed that in each of the several applications of my improved process, the heat is for the most part' applied to or concentrated upon the bond terminal, the incandescent electrode being.

regarded in its general aspect simply as an external heat source. Such bond terminal then conducts the heat thus received to the portion of the railA that it is desired immediately to adect, and being of a character such to permit this conduction at a Very rapid rate, more. rapidly, in other Words, than the heat can be dissipated through the rail, it is found that the contacting superlicies of the two bodies are raised practically simultaneously to the required welding temperature. This it will be obvious is accomplished without the loss of time and waste of energy that would be incidental to the raising to such temperature of the entire sec tion of rail adjacent to the portion to which the bond is to be attached.

ln the foregoing description of my process, l have made no yreference to the use of either braze, flux or other .cementing material; it will of course be understood that the introduction of any such material is optional with the user, and if in certain cases it be found to facilitate the operation, would be recommended. It is not necessary, however, to the securing of a thorough union between the materials, and so need be referred to only in this incidental fashion.

1t will be understood, in conclusion, that in referring herein to the material of the bond terminal as being pressed radially outwardfagainst the bounding aperture in the rail, I include equally, the various previously described ways in which this pressure is obtained; whether by the contact of the electrode against the projecting louter end of the solid bond terminals of Figs. l and 7, or that of the projection (0*, el, e8) against the inner walls of the hollow terminals of Figs. 5, 8, 9 and 10, or that of rod c. acting in conjunction with such a projection, against the inner walls of the tubular terminal of Fig. G.

Other lmodes of applying the principle of my invention may be employed instead of the one explained, change heilig made as regards the process herein disclosed, provided the step or steps stated by any one of the following claims or the equivalent of such stated step or steps be employed.

l therefore particularly point out and distinctly claim as my invention 1. The method of uniting metal bodies, which consists in inserting a terminal of one body in an aperture in the other body, there upon applying heat from an external source to such terminal, whereby such terminal and the surface of the second body bounding the aperture therein are brought to a welding temperature, and simultaneously pressing thematerial of such terminal against such bounding surface, substantially as described.

2. The method of uniting metal bodies, which consists in inserting a terminal of one body in an aperture in the other body, there* upon applying heat from an external source to such terminal, whereby such terminal and the surface of the second body bounding the aperture therein are brought to a welding temperature, and simultaneously pressing the material of such terminal from within radially outward against such bounding surface, substantially as described.

3. rlthe method of homogeneously uniting metal bodies having unlike heat conductivities, which consists in inserting a terminal of the body of greater heat conductivity in an aperture in the other body, thereupon applying heat from an external source to such terminal, whereby such terminal and the surface of the second body bounding the aperture therein are brought to a welding temperature, and simultaneously pressing the material of such terminal against such bounding surface, substantially as described.

si. The method of homogeneously'uniting metal bodies having unlike characteristics as to fusibility, the more readily fusible body having also the greater heat conductivity, which consists in inserting a terminal of the first or more readily fusible body in an aperture of the second body, thereupon applying heatfrom an external source to such terminal, whereby such terminal and the snrface of the second body bounding the aperture therein' are brought to a welding temperature, and simultaneously pressing the material of such terminal radially outward against such bounding surface, substantially as described.

5. rll`he method of homogeneously uniting metal bodies of unlike masses and different temperatures of fusion, the smaller mass having both the lower temperature of fusion and the greater heat conductivity; which consists in inserting a terminal of said first or smaller body in an aperture in the second body; thereupon applying heat from an eX- ternal source to such terminal; thereby eflectively heating the surface of said second body bounding the aperture therein by conduction through such terminal, whereby such terminal and bounding surface are censos brought to a Welding temperature; and simultaneously pressing the material of such terminal from Within radially outward against such bounding surface, substantially as described.

G. The method of homogeneously uniting metal bodies having unlike characteristics as to fusibility, the more readily fusible body having also the greater heat conductivity; which consists in inserting a terminalof the first or more readily fusible body in an aperture in the second body at the desired point of union; directly heating such terminal by pressing an electrode of high resistance against the same and thereupon passing a heating electric current through said electrode until a high temperature is produced; thereby eHectiVely heating the surface of the second body bounding the aperture therein by conduction through such terminal, whereby such terminal and bounding surface are brought to a Welding temperature; and simultaneously pressing the material of such terminal from within radially outward against such bounding surface, substantially as described.

7. The method of homogeneously uniting metal bodies having unlike masses and different temperatures of fusion, the smaller mass having both the lower temperature of fusion and the greater heat conductivity; which consists in inserting a terminal of said smaller body in an aperture in said larger body at the desired point of union; directly heating such terminal by pressing an electrode of high resistance against the same and then passing a heating electric current through said electrode until a high temperature is produced; thereby effectively heating the surface of said larger body bounding the 'aperture therein by conduction through such terminal, whereby such terminal and bounding surface are brought to a welding temperature; and simultaneously pressing the material of such terminal from within radially outward against such bounding surface, substantially as described.

8. The method of homogeneously uniting metal bodies having unlike characteristics as to fusibility, the more readily fusible body having also the greater heat conductivity; which consists in inserting a terminal of the first or more readily fusible body in an aperture in the second body at the desired point of union; directly heating such terminal by pressing an electrode of high re sistance against the same and thereupon passing an electric current through said electrode and terminal, such cnrrcnt beingadapted to produce a high temperature in said electrode; thereby effectively heating the surface of the second body bounding` the aperture therein from the same electrode by conduction through the first body, whereby such terminal and bounding surface are lIO terminal from Within brought to a Welding temperature; and simultaneously pressing the material of such terminal from Within radially outward against such bounding surface, substantially as described.' p

9. The method of homogeneously uniting metal bodies of unlike masses and-diierent temperatures of fusion, the smaller fnass having both the lower temperature Aof fusion and the greater heat conductivity; which consists in inserting a terminal of said smaller body in an aperture in said larger -body at the desired point of union; directly heating such terminal by pressing. an electrode of high resistance against the same and then ing adapted to produce a high temperature in said electrode; thereby effectively heating the surface of said larger body bounding the aperture therein from the same electrode by conduction through such termina-l,l whereby such terminal and bounding surface are brought to a `Welding temperature; .andvsimult-aneously pressing the material of such radially outward passing an electric current through" said electrode and terminal, such current be- 'against suchbounding surface, substantially as described.

l0. The method of homogeneously uniting a bond to a rail, which consists in insertingv a terminal ofthe bond in an aperture in the rail at the desired point of union; directly heating suchterminal by pressingA an elecsuch terminal and bounding surface are brought to awelding temperature; and simultaneously pressing the material of such terminal from Within, .radially outward against such bounding surface, substantially, as described. Y

Signed by me,this 8th day of June, 1909.

- WILLIAM B. CLEVELAND.

Attested by- ANNA L. GILL,

JNO. F. OBERLIN. 

